Method of producing wet process phosphoric acid

ABSTRACT

AN IMPROVED METHOD AND APPARATUS FOR MANUFACTURING WET PROCESS PHOSPHORIC ACID WHEREIN THE REACTANTS WHICH INCLUDE PHOSPHATE ROCK AND SULFURIC ACID ARE REACTED IN A COMBINATION REACTOR AND COOLER UNIT CONTAINING A BODY OF REACTION SLURRY HAVING A SUBSTANTIALLY UNIFORM LEVEL OF CALCIUM SULFATE SUPERSATURATION THROUGHOUT. THE BODY OF REACTION SLURRY IS CIRCULATED IN A PRIMARY FLOW CIRCUIT IN WHICH SUBSTANTIALLY THE ENTIRE BODY IS EXPOSED TO A SUBATMOSPHERIC PRESSURE MAINTAINED IN THE COMBINATION REACTOR AND COOLER UNIT AT A FIRST RATE OF FLOW AT LEAST EQUAL TO 20% OF THE TOTAL MASS OF REACTION SLURRY PER MINUTE AND PREFERABLY FROM 100% TO 200% OF THE TOTAL MASS OF REACTION SLURRY PER MINUTE. SIMULTANEOUSLY, A PORTION OF THE BODY OF REACTION SLURRY IS CIRCULATED THROUGH A SECONDARY FLOW CIRCUIT AT A FLOW RATE NOT GREATER THAN 50% OF THE FIRST FLOW RATE AND PREFERABLY NOT GREATER THAN 10% OF SUCH FIRST FLOW RATE. WHILE IN SUCH SECONDARY FLOW CIRCUIT, THE REACTION SLURRY IS HEATED TO INCREASE THE TEMPERATURE NOT MORE THAN 20*F., AND PREFERABLY NOT MORE THAN 5*F., ABOVE THE AVERAGE BULK TEMPERATURE OF THE BODY OF REACTION SLURRY. THE RESIDENCE TIME OF THE REACTION SLURRY IN THE SECONDARY FLOW CIRCUIT DURING AND AFTER HEATING DOES NOT EXCEED 30 SECONDS AND PREFERABLY IS NOT GREATER THAN 10 SECONDS. THE HEATED REACTION SLURRY IS RETURNED TO THE COMBINATION REACTOR AND COOLER UNIT AT A LOCATION AT WHICH IT WILL BE SUBSTANTIALLY INSTANTEOUSLY COOLED BY CONTACT WITH SAID CIRCULATING BODY OF REACTION SLURRY CONTAINED THEREIN, RESULTING IN AN ADDITIONAL HEAT INPUT INTO SAID BODY OF REACTION SLURRY WITHOUT ADVERSELY AFFECTING THE SUBSTANTIALLY UNIFORM LEVEL OF CALCIUM SULFATE SUPERSATURATION THEREIN.

May 30, 1972 R. E. BERGSTROM v3,555,413

METHOD OF PRODUCING WET PROCESS PHOSPHORIC ACID Filed Aug. 25, 1969 INVENTOR RALPH E. BERG STROM BY fl wf m 92% ATT'YS.

United States Patent METHOD OF PRODUCING WET PROCESS PHOSPHORIC ACID Ralph E. Bergstrom, Chicago, Ill., assignor to Whiting Corporation Continuation-impart of application Ser. No. 607,692,

Jan. 6, 1967. This application Aug. 25, 1969, Ser. No. 857,276

Int. Cl. C0lb 25/22 US. Cl. 23-165 15 Claims ABSTRACT OF THE DISCLOSURE An improved method and apparatus for manufacturing wet process phosphoric acid wherein the reactants which include phosphate rock and sulfuric acid are reacted in a combination reactor and cooler unit containing a body of reaction slurry having a substantially uniform level of calcium sulfate supersaturation throughout. The body of reaction slurry is circulated in a primary flow circuit in which substantially the entire body is exposed to a subatmospheric pressure maintained in the combination reactor and cooler unit at a first rate of flow at least equal to 20% of the total mass of reaction slurry per minute and preferably from 100% to 200% of the total mass of reaction slurry per minute. Simultaneously, a portion of the body of reaction slurry is circulated through a secondary flow circuit at a flow rate not greater than 50% of the first flow rate and preferably not greater than 10% of such first flow rate. While in such secondary flow circuit, the reaction slurry is heated to increase the temperature not more than 20 F., and preferably not more than F., above the average bulk temperature of the body of reaction slurry. The residence time of the reaction slurry in the secondary flow circuit during and after heating does not exceed 30 seconds and preferably is not greater than seconds. The heated reaction slurry is returned to the combination reactor and cooler unit at a location at which it will be substantially instantaneously cooled by contact with said circulating body of reaction slurry contained therein, resulting in an additional heat input into said body of reaction slurry without adversely affecting the substantially uniform level of calcium sulfate supersaturation therein.

BACKGROUND AND DESCRIPTION OF THE INVENTION This application is a continuation-in-part of my application Ser. No. 607,692, filed Ian. 6, 1967, now abandoned and entitled Improved Phosphoric Acid Reactor and Method.

The present invention relates to improvements and innovations in the manufacture of wet process phosphoric acid. More particularly, this invention is concerned with an improved method and apparatus for directly producing concentrated wet process phosphoric acid. In accordance with the practice in the wet process phosphoric acid industry, reference to phosphoric acid strength in this application will be made by identifying the equivalent P 0 concentration.

In the manufacture of phosphoric acid by conventional wet process methods, phosphate rock is reacted with sulfuric acid to produce a phosphoric acid product having an equivalent P 0 concentration of about 30% by weight. This product is usually concentrated in an evaporator to provide a product having an equivalent P 0 concentration of approximately 54% or to the superphosphoric level, viz, wherein the equivalent P 0 concentration is approximately 68% or more.

3,666,413 Patented May 30, 1972 The installation and operation expenses for a conventional phosphoric acid reactor and evaporator system are costly since such involve the installation and operation of two separate units, namely, a reactor and a forced circulation or equivalent evaporator. The present invention overcomes the disadvantages inherent in constructing and operating two separate units to produce a single product by providing a unique combination reactor and cooler unit which can be operated by a minimum of plant personnel to directly produce a concentrated wet process phosphoric acid product.

The practice of the present invention offers, as an important advantage, the ability to a accommodate increased amounts of water in the slurry body from such sources as the use of a wet phosphate rook feed and the use of increased amounts of wash water which is recycled back to the wet process reaction slurry with the return weak phosphoric acid. With conventional wet process phosphoric acid manufacturing methods, only a limited amount of heat from the exothermic reactions in the slurry is available for vaporizing the water in the system to produce a wet process phosphoric acid product having a desired P 0 concentration. Accordingly, with conventional methods it is necessary to limit the amount of water introduced into the system by using dry phosphate rock and limiting wash water to the filter so that calcium sulfate leaving the system contains 1% or more water soluble P 0 losses. Increasing the allowable water rate in conventional systems would reduce this loss but would be accompanied by the disadvantage of resulting in a more dilute acid product.

In accordance With the present invention, an improved wet process phosphoric acid method and apparatus are provided wherein a main body of reaction slurry is continuously circulated in a predetermined primary flow circuit while a portion of the body of reaction slurry is withdrawn from the main slurry body, heated and then returned thereto. In particular, the main body of reaction slurry is circulated in a predetermined flow path adapted to expose substantially the entire body of reaction slurry to a subatmospheric pressure at a first rate of flow which is at least equal to 20%, and preferably from to 200%, of the total mass of such body of reaction slurry per minute. This high circulation rate in combination with the controlled amount of evaporative cooling operates to provide a substantially uniform level of calicum sulfate supersaturation throughout the body of reaction slurry. Simultaneously, the body of reaction slurry circulated through the secondary flow circuit is circulated at a flow rate not greater than 5 0% of the first flow rate and preferably not greater than 10% of such first flow rate. While in such secondary flow circuit, the reaction slurry is heated to a temperature of not more than 20 F., and preferably not more than 5 F., above the average bulk temperature of the body of reaction slurry. The residence time in the secondary flow circuit during and after heating is sufficiently short so that the calcium sulfate crystals present in the slurry circulated therethrough do not substantially dissolve and therefore the level of calcium sulfate supersaturation is not materially altered. Typically, such residence time at elevated temperatures is less than 30 seconds and preferably such residence time is not greater than 10 seconds. The heated reaction slurry from the secondary flow circuit is returned to the main body of reaction slurry at a location at which it will be substantially instantaneously cooled by contact with the primary flow circuit of the body of reaction slurry, thereby resulting in an additional heat input into the body of reaction slurry without adversely affecting the substantially uniform level of calcium sulfate supersaturation therein.

It is, therefore, an object of the present invention to provide an improved method and apparatus for the manufacture of wet process phosphoric acid.

Another object of the present invention is to provide an improved method and apparatus for directly producing a concentrated wet process phosphoric acid product.

Another object of the present invention is to provide an improved phosphoric acid reactor which can produce a phosphoric acid product having an equivalent P concentration limited only by the corrosive resistance of the materials of construction.

Another object of the present invention is to provide an improved method and apparatus for the manufacture of wet process phosphoric acid wherein controlled amounts of heat are externally introduced into the reactor for directly and efficiently producing a wet process phosphoric acid product having an equivalent P 0 weight concentration of over 30% Another object of the present invention is to provide an improved method and apparatus for the manufacture of wet process phosphoric acid wherein wet phosphate rock feed can be accommodated with increased product yields and at an increased equivalent P 0 product concentration.

Another object of the present invention is to provide an improved method and apparatus for the manufacture of wet process phosphoric acid in which increased amounts of wash water can be added for washing the calcium sulfate crystals on the filter produced by the reaction without reducing the equivalent P 0 concentration of the product, thereby providing an increased product yield.

Another object of the present invention is the provision of a combination reactor and cooler unit for carrying out the manufacture of phosphoric acid by wet process techniques which unit occupies less space, requires fewer moving parts and is substantially less expensive to build, operate and maintain than conventional installations thereby substantially lowering installation and operating costs.

Other and further objects of the present invention Will be apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:

FIG. 1 is a partially schematic and partially diagrammatic view of apparatus for producing phosphoric acid by wet process techniques in a combination reactor and slurry cooler unit embodying the present invention.

Referring to the drawings, and with particular reference to FIG. 1, the numeral 11 general designates a Wet process phosphoric acid reactor system embodying principles of the present invention equipped with a combination reactor and cooler unit 12 having a secondary flow line 13 in which a portion of slurry is withdrawn from the reactor and cooler unit 12, heated in a heat exchanger 14 and then returned to the interior of the react0r and cooler unit 12.

In the illustrated embodiment, ground phosphate rock is fed from a rock feeding conveyor device 16 into a mixer 17 which receives metered amounts of return acid via return acid feed line 18. The return acid and the rock slurry are then dispensed through reactor feed line 19 into the combination reactor and cooler unit 12 at feed inlet 20 adjacent the bottom thereof. This location in the reactor and cooler unit 12 is characterized by high turbulence principally developed by a forced circulation means in the form of a propeller 21 which, in the illustrated embodiment, is mounted to the lower end of a drive shaft 22 operatively connected to a suitable motor (not illustrated).

As shown in FIG. 1, the reactor and cooler unit 12, which constitutes a preferred embodiment of the present invention, includes a fixed diameter midsection 23 closed at its upper and lower ends by frusto-conical top and bot- 4 mize rotation of the body of reaction slurry contained therein. The upper end of the draft tube 26 preferably terminates slightly below the normal operating liquid level within the unit 12. Propeller 21 is positioned and rotated so that liquid in the reactor and cooler unit 12 will be drawn in from the bottom, upwardly through the draft tube 26 and downwardly along the outside thereof in a primary flow pattern which, in the illustrated embodiment, is a toroidal flow pattern as is schematically indicated in FIG. 1 by the arrows.

A uniform level of supersaturation throughout the body of reaction slurry in the combination reactor and cooler unit 12 is maintained by circulating the slurry body in the primary flow pattern wherein substantially the entire body of reaction slurry is exposed to a subatmospheric pressure maintained in the unit 12 at a flow rate which is at least equal to 20% of the total mass of reaction slurry per minute and which is preferably from to 200% of the total mass of reaction slurry per minute.

Slurry level in the reactor-cooler unit 12 is maintained by an overflow device 32 which discharges the overflow liquid by gravity into a filter feed tank 31. Vapors emitted from the reaction slurry are transmitted through vapor overhead connection line 33 to a condenser 34 having a cold water inlet 35, condensate discharge outlet 36, and steam inlet 37.

The temperature of the body of reaction slurry is effectively controlled by the subatmospheric pressure maintained in the freeboard space above the slurry body. In this regard, it should be noted that the improved method and apparatus of the present invention can be used to manufacture wet process acid at temperatures of from F. to 230 F. and above. Accordingly, this invention finds advantageous applicability to the wet process phosphoric acid systems wherein gypsum (CaSO -2H O) and/or the hemihydrate form of calcium sulfate (CaSO /2H O) are formed.

In the illustrated embodiment, sulfuric acid is delivered into the combination reactor and cooler unit 12 through acid inlet 38 which projects into the interior of frustoconical top 24 and carried an annular spray head 39 equipped with a plurality of discharge openings 40 in the bottom thereof enabling sulfuric acid to be efiiciently sprayed and distributed throughout the interior of the freeboard space in the reactor and cooler unit 12.

In accordance with the present invention, a portion of the slurry in combination reactor and cooler unit 12 is circulated through a secondary flow circuit in the form of the sidearm loop 13 which includes heat exchanger 14. After being heated, the slurry is returned to the combination reactor and cooler unit 12, preferably being introduced in the lower end of frusto-conical bottom member 25, as generally designated by the reference numeral 40, wherein it is uniformly admixed with the incoming phosphate rock and acid slurry entering through inlet 20 in the primary flow circuit.

In the illustrated embodiment, outlet 30 communicates with loop 13 which includes an axial flow or equivalent pump 41 having its discharge end communicating directly with the tube inlet header 42 of heat exchanger 14. Upon being heated, the slurry exists through tube header outlet 43 and returns to the combination reactor and cooler unit 12 via the secondary circuit return line portion 13a. Steam or other suitable heating medium is introduced into heat exchanger 14 in a conventional manner as is generally shown at 44 and exists at condensate outlet 45.

The portion of the body of reaction slurry circulated through the secondary flow circuit is heated to a temperature of not more than 20 F., and preferably not more than 5 F., above the average bulk temperature of the body of reaction slurry in the combination reactor and cooler unit 12. This relatively low temperature increase is employed in conjunction with a residence time of the reaction slurry in the secondary flow circuit which does not exceed 30 seconds and is preferably not greater than 10 seconds in order to insure that there is no appreciable change in the supersaturation level of the reaction slurry circulated therethrough. In other words, the heated portion of the reaction slurry is returned to the main body of reaction slurry and cooled therein before the calcium sulfate precipitate contained therein appreciably dissolves. The fiow rate through the secondary flow circuit should not exceed 50% of the flow rate of the entire body of reaction slurry in the primary flow circuit. Preferably, the fiow rate through the secondary fiow circuit will be equal to, or less than, 10% of such primary flow rate.

Filter feed tank 31 is provided with an agitator 46 which serves to keep the contents of the filter feed tank 31 uniformly dispersed. In the illustrated embodiment, agitator 46 is mounted to the upper end of a shaft 47 which passes through a seal 48 and is driven in known manner.

Reaction slurry is removed at a uniform rate from filter feed tank 31 by a pump 49 connected to discharge outlet 50 located in the bottom of sidewall 31a of filter feed tank 31. Pump 49 discharges the reaction slurry through discharge pipe 51 into the first stage of a series of filters 52 which, in the illustrated embodiment, consists of three filter units 53-55. In the first filter unit 53, concentrated phosphoric acid is separated from the crystals and is drawn off through the bottom through filtrate pipe 56 into vacuum tank 57. This concentrated phosphoric acid is discharged through line 58 into storage tank 59 and is selectively removed therefrom via product discharge outlet 60. The reaction slurry, from which a substantial portion of the concentrated phosphoric acid has been removed, passes from the filter unit 53 into the second filter unit 54 which also receives wash water from filter unit 55 through wash water return line 68 as is more fully described below. Weak phosphoric acid is drawn off from the filter unit 54 into vacuum tank 61 and is discharged therefrom into receiving tank 62 via communicating line 63. Weak phosphoric acid is then discharged from receiving tank 62 into return acid feed line 18 for mixing with phosphate rock feed, which, due to the increased evaporative capacity of the combination reactor and cooler unit, can be in the form of socalled wet phosphate rock without necessitating a reduction in the P level of the phosphoric acid product and without reducing the product yield.

The slurry which passes through filter unit 54 into the third and last filter unit 55 is washed with wash water from a suitable source 64. The washed calcium sulfate crystals are discharged from filter unit 55 either to waste or any further utilization which may be desired. Wash water is drawn into vacuum receiver 65 through intercommunicating line 55a and is discharged therefrom into receiving tank 66 via line 67. This wash water is returned to filter unit 54 by return line 68. All of the vacuum receivers 57, 61 and 65 are connected to a common vacuum header 69.

An important feature of the present invention concerns the fact that substantially greater quantities of water may be used for washing the filter cake in filter units 53-55 without adversely affecting the concentration of the phosphoric acid product concentration since the excess water is removed with other vapors in combination reactor and cooler unit 12. This advantageous use of increased amounts of wash water substantially reduces phosphoric acid loss at this source and produces greater product yields at higher concentrations than are obtained with conventional wet process reactor systems.

The following detailed working example describing reactor system 11 of FIG. 1 will serve to illustrate the nature of the invention and the manner in which the evaporator system thereof can be operated.

Example I The combination reactor and cooler unit 12 may have a height of 25 feet with cylindrical section 23 having a diameter of 18 feet. The draft tube 26 would have a diameter of 4 feet and would project down to within about 2 feet of the bottom of reactor-cooler unit 12. The normal liquid operating level within tank 12 should be about 10 feet. The condenser 34 would be capable of producing 22-24 inches of vacuum within the head space of the combination reactor and cooler unit 12.

The heat exchanger 14 may have an overall height of 20 feet and contain 55 heat exchanger tubes formed of impervious graphite, each having an inside diameter of 1 /2 inches and a length of 18 feet. The pump 41 would be rated at 2,150 gallons per minute (g.p.m.) and be driven by a motor having 20 horsepower. Filter feed tank 31 can have a diameter of 18 feet and a sidewall height of 20 feet for handling a normal liquid operating level of 15 feet.

The operating conditions may be summarized as follows for an installation having a capacity of t.p.d. P 0 at a concentration of 40% P 0 Typical central Florida phosphate rock is introduced through the conveyor 16 into the mixer 17 at a rate of 330 t.p.d. while 679 t.p.d. of return phosphoric acid are admixed therewith. The resulting slurry is fed through reactor feed line 19 into the bottom of reactor-cooler 12.

Sulfuric acid having a concentration of 93% is fed at the rate of 276 t.p.d. into the acid inlet 38 for discharge into the slurry contained in reactor-cooler 12 while propeller 21 is driven at approximately 100 rpm. by a 25 horsepower motor. The flow through the primary flow circuit would be approximately 21,500 g.p.m. and the flow through the secondary flow circuit would be approximately 2,150 g.p.m. with approximately 4,700,000 B.t.u. of heat being added to the slurry flow per hour. The heat from the reaction would be approximately 55 million B.t.u.s per hour. The total heat removed by the reactorcooler unit would be 59,700,000 B.t.u.s per hour. The reaction slurry to be processed in the filter feed tank is Withdrawn through the overflow device 32 into filter feed tank 31 at a 40% P 0 concentration and flow rate of approximately 1,166 t.p.d. Reaction slurry containing crystals dispersed in concentrated phosphoric acid are withdrawn from filter feed tank 31 through outlet 50 at an equal rate of 1,166 t.p.d. and discharged to filter series 52. Wash water at a rate of 457 t.p.d. is introduced through line 64. 250 t.p.d. of phosphoric acid having a concentration of 40% P 0 are produced along with 465 t.p.d. of calcium sulfate crystals.

In the foregoing specification, a detailed description of two specific embodiments of the present invention have been fully set forth. It will, however, be apparent to those skilled in the art that variations and modifications may be made therefrom without departing from the spirit and scope of the present invention. Accordingly, this invention is to be limited only by the scope of the following claims.

I claim:

1. An improved method of making wet process phosphoric acid from reactants which include phosphate rock, sulfuric acid and water, said process comprising the steps of: continuously adding said reactants to a body of reaction slurry contained in a combination reactor and cooler, said reactants upon being combined in said body of reaction slurry generating heat from exothermic reactions which occur therein; continuously maintaining a subatmospheric pressure above a portion of said body of reaction slurry to induce evaporative cooling thereof; continuously circulating substantially the entire body of reaction slurry in a primary flow circuit adapted to expose substantially the entire body of reaction slurry to said subatmospheric pressure at a first rate of flow; continuously circulating a portion of said body of reaction slurry to said subatmospheric pressure at a first rate of flow; continuously circulating a portion of said :body of reaction slurry through a secondary flow circuit at a rate which does not exceed 50% of said first rate of flow; heating said portion of reaction slurry in said secondary flow circuit to an elevated temperature of not more than 20 F. above the average bulk temperature of said body of reaction slurry, said portion of reaction slurry in said secondary circuit being maintained at said elevated temperature for not longer than 30 seconds; said evaporative cooling of said body of reaction slurry being maintained in substantial balance with the rate at which heat is generated from said exothermic reactions and from the heating of the reaction slurry in said secondary flow circuit; and, continuously withdrawing a portion of said reaction slurry from said combination reactor and cooler.

2. An improved method of making wet process phosphoric acid from reactants which include phosphate rock, sulfuric acid and water, said process comprising the steps of: continuously adding said reactants to a body of reaction slurry contained-in a combination reactor and cooler, said reactants upon being combined in said body of reaction slurry generating heat from exothermic reactions which occur therein; continuously maintaining a subatmospheric pressure above a portion of said body of reaction slurry to induce evaporative cooling thereof; continuously circulating substantially the entire body of reaction slurry in a primary flow circuit adapted to expose substantially the entire body of reaction slurry to said subatmospheric pressure at a first rate of flow at least equal to 20% of the total mass of said body of reaction slurry per minute; continuously circulating a portion of said body of reaction slurry through a secondary flow circuit, the rate of flow of said portion of reaction slurry circulated through said secondary flow circuit not exceeding 50% of said first rate of flow; heating said portion of reaction slurry in said secondary flow circuit to an elevated temperature of not more than 20 F. above the average bulk temperature of said body'of reaction slurry, said portion of reaction slurry in said secondary circuit being maintained at said elevated temperature for not longer than 30 Seconds; said evaporative cooling of said body of reaction slurry being maintained in substantial balance with the rate at which heat is generated from said exothermic reactions and from the heating of the reaction slurry in said secondary flow circuit; and, continuously withdrawing a portion of said reaction slurry from said combination reactor and cooler unit.

3. The improved method of claim 2 wherein the rate of flow of said portion of reaction slurry circulated through said secondary flow circuit does not exceed 10% of said first rate of How.

4. The improved method of claim 2 wherein said first rate of flow is from approximately 100% to 200% of the total mass of said body of reaction slurry per minute.

5. The method of claim 2 wherein said portion of reaction slurry in said secondary flow circuit is heated to a temperature of not more than 5 F. above the average bulk temperature of said body of reaction slurry.

6. The improved method of claim 2 wherein said portion of reaction slurry is maintained at said elevated temperature in said secondary circuit for not longer than seconds.

7. An improved method for making wet process phosphoric acid from reactants which include phosphate rock, sulfuric acid and Water, said process comprising the steps of: continuously adding said reactants to a body of reaction slurry having a substantially uniform level of calcium sulfate supersaturation throughout, which body of reaction slurry is contained in a combination reactor and cooler unit, said reactants upon being combined in said body of reaction slurry generating heat from exothermic reactions which occur therein, said combination reactor and cooler unit including a vessel having a top enclosure means defining an enclosed freeboard space above said liquid level of said body of reaction slurry, said combination reactor and cooler unit having flow directing means and forced circulation means operatively associated therewith for continuously circulating substantially the entire body of reaction slurry in said vessel in a primary fiow pattern adapted to expose substantially 8 the entire :body of reaction slurry in said combination reactor and cooler unit'to said freeboard space at a first rate of flow at least equal to 20% of the total mass of said body of reaction slurry per minute; continuously circulating a portion of said body of reaction slurry through a secondary flow circuit having an outlet and inlet communicating with said vessel, the rate of flow of said portion of reaction slurry through said secondary circuit not exceeding 50% of said first rate of flow; heating said portion of reaction slurry in said secondary flow circuit to a temperature of not more than 20 F. above the average bulk temperature of the reaction slurry in said vessel, said portion of reaction slurry having a residence time in said secondary circuit during and after heating of not longer than 30 seconds prior to being returned to said vessel, said outlet of said secondary flow circuit communicating with said vessel at a location wherein said heated portion of reaction slurry will be returned to said body of reaction slurry in said vessel below the liquid level thereof; maintaining said freeboard space at a predetermined subatmospheric pressure and conducting evaporative cooling of said body of reaction slurry at a rate which is substantially in balance with the total heat input into said body of reaction from said exothermic reactions and from the heating of said reaction slurry in said secondary flow circuit; and, continuously withdrawing a portion of said reaction slurry from said combination reactor and cooler unit.

8. The improved method of claim 5 wherein said first rate of flow is from approximately to 200% of the total mass of said body of reaction slurry in said vessel per minute.

9. The improved method of claim 5 wherein the rate of flow of said portion of reaction slurry circulated through said secondary flow circuit does not exceed 10% of said first rate of flow.

10. The improved method of claim 5 wherein said portion of reaction slurry in said secondary flow circuit is heated to a temperature of not more than 5 F. above the average bulk temperature of the reaction slurry in said vessel.

11. The improved method of claim 5 wherein said portion of reaction slurry has a residence time in said secondary circuit of not longer than 10 seconds.

12. The improved method of claim 5 wherein said heated portion of reaction slurry is returned to said body of reaction slurry in said vessel adjacent said forced circulation means.

13. An improved method for making wet process phos phoric acid from reactants which include phosphate rock, sulfuric acid and water, said process comprising the steps of: continuously adding said reactants to a body of reaction slurry contained in a combination reactor and cooler unit, said reactants upon being combined in said body of reaction slurry generating heat from exothermic reactions which occur therein, said combination reactor and cooler unit including a vessel having a top enclosure means defining an enclosed freeboard space above the liquid level of said body of reaction slurry, said combination reactor and cooler unit having an upright draft tube disposed within the body of reaction slurry and forced circulation means associated with said draft tube for continuously circulating substantially the entire body of reaction slurry in said vessel in a primary flow pattern adapted to expose substantially the entire body of reaction slurry in said combination reactor and cooler unit to said freeboard space at a first rate of flow of from approximately 100% to 200% of the total mass of said body of reaction slurry in said vessel per minute; continuously circulating a portion of said body of reaction slurry through a secondary flow circuit having an outlet and inlet communicating with said vessel, the rate of flow of said portion of reaction slurry through said secondary circuit not exceeding 10% of said first rate of flow; heating said portion of reaction slurry in said secondary llow circuit to a temperature of not more than 20 F. above the average bulk temperature of the reaction slurry in said vessel, said portion of reaction slurry having a residence time in said secondary circuit during and after heating of not longer than 30 seconds prior to being returned to said vessel, said outlet of said secondary flow circuit communicating with said vessel at a location wherein said heated portion of reaction slurry is uniformly dispersed in said body of reaction slurry below the liquid level thereof; maintaining said freeboard space at a predetermined subatmospheric pressure and conducting evaporative cooling of said body of reaction slurry at a rate which is substantially in balance with the total heat input into said body of reaction slurry from said exothermic reactions and from the heating of said reaction slurry in said secondary flow circuit; and continuouesly withdrawing a portion of said reaction slurry from said combination reactor and cooler unit.

14. The improved method of claim 11 wherein said portion of reaction slurry in said secondary flow circuit is heated to a temperature of not more than 5 1F. above the average bulk temperature of the reaction slurry in said vessel.

15. The improved method of claim 12 wherein said portion of reaction slurry has a residence time in said secondary circuit of not longer than 10 seconds.

References Cited UNITED STATES PATENTS 1,831,121 11/1931 Kermer l5927 10 1,927,555 9/1933 Oetken 23165 X 3,118,731 1/1964 Svanoe 23-165 3,416,889 12/1968 Caldwell 23-165 3,522,003 7/1970 Lopker 23--165 3,522,004 7/1970 Lopker 23-165 15 OSCAR R. VERTIZ, Primary Examiner G. A. HELLER, Assistant Examiner US. Cl. X.R. 23 122 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTIGN Patent No. 3,666 ,4l Dat d May 30, 1972 Inventor(s) Ralph E. Bergstrom It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 2, line 13, delete "a" Column 2, line 46, "calicum" should read calcium-- Column 4, line 61, "exists" should read exits Column 4, line 66, "exists" should read -exits-- Column 8, line 29, "5" should read 7- Column 8, line 33, "5" should read 7 Column 8, line 37, "5" should read -7 Column 8, line 42, "5" should read -7- Column 8, line 45, "5" should read -7 Column 9, line 18, "11" should read -l3 Column 10, line 3, "12'' should read l3- Signed and sealed this 6th day of February 1973.

(SEAL) Attest:

EDWARD M. FLIZTCIIERJR. ROBERT GOTTSCHALK Attestlng Officer Commissioner of Patents 'ORM PC4050 (10-69) USCOMM-DC 60376-1 69 8 U.54 GOVERNMENT PRINTING OFFICE: I969 O-365334. 

